Systems for axle arm

ABSTRACT

Systems are provided for an axle arm including a lubricant reservoir and a driveshaft. In one example, system may include a lubricant reservoir of an axle arm comprising a fill line at an edge of a driveshaft, wherein a central axis of the lubricant reservoir is misaligned with a central axis of the driveshaft.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S.Non-Provisional patent application Ser. No. 17/450,051, entitled“Systems for Axle Arm”, and filed on Oct. 5, 2021, and claims priorityto German Utility Model Application No. 202020107271.4, entitled“Systems for Axle Arm”, and filed on Dec. 16, 2020. The entire contentsof each of the above-listed applications are hereby incorporated byreference for all purposes.

TECHNICAL FIELD

The present description relates generally to systems for an axle arm,more specifically to an axle arm arrangement configured to reduce anamount of oil in the axle arm.

BACKGROUND AND SUMMARY

Vehicles may include a driveshaft configured to transfer power from amotor to one or more wheels. The driveshaft may receive lubricant from alubrication system fluidly coupled to other lubricated vehiclecomponents. Lubricant demand may vary between components of thelubrication system, resulting in changes in lubricant flow. During someconditions, multiple components may demand higher lubricant flows. Thus,there may be a demand to decrease lubricant use in one or morecomponents to increase an availability of lubricant.

Previous approaches may include a lubricant reservoir including acentral axis aligned with an axis of the driveshaft. This design leadsto a relatively high amount of lubricant within the arm. Thus, it may bedesired to reduce an amount of lubricant held within an arm of thedriveshaft while maintaining a desired lubrication and structuralrigidity.

In one example, the issues described above may be addressed by a systemcomprising an oil reservoir of an axle arm including a fill line at anedge of a driveshaft, wherein a central axis of the oil reservoir ismisaligned with a central axis of the driveshaft. In this way, an amountof lubricant below the central axis of the driveshaft is reduced.

As one example, the central axis of the driveshaft is arranged above thecentral axis of the lubricant reservoir. A first distance measured froma lower perimeter of the lubricant reservoir to the central axis of thedriveshaft is less than a second distance measured from an upperperimeter of the lubricant reservoir to the drive shaft. Furthermore,the axle arm may include where the first distance is less than adiameter of the driveshaft. By shaping the reservoir in this way, anamount of lubricant below the driveshaft is reduced without impactingthe axle arm performance and strength.

It should be understood that the summary above is provided to introducein simplified form a selection of concepts that are further described inthe detailed description. It is not meant to identify key or essentialfeatures of the claimed subject matter, the scope of which is defineduniquely by the claims that follow the detailed description.Furthermore, the claimed subject matter is not limited toimplementations that solve any disadvantages noted above or in any partof this disclosure.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows an example vehicle system.

FIG. 2 shows an example configuration of an axle arm.

FIG. 3 shows a first cross-sectional view along a cutting plane A-A ofthe axle arm illustrating a lubricant reservoir and a driveshaft.

FIG. 4 shows a second cross-sectional view along a cutting plane B-B ofthe axle arm illustrating the lubricant reservoir and the driveshaft.

FIG. 5 shows an amount of lubricant arranged in the lubricant reservoir.

FIGS. 2-5 are shown approximately to scale.

DETAILED DESCRIPTION

The following description relates to systems for an axle arm. The axlearm may include a lubricant reservoir and a driveshaft configured totransfer power to wheels of a vehicle, as shown in FIG. 1. An embodimentof the axle arm is shown in FIG. 2. A first cross-sectional view of theaxle arm taken along a cutting plane A-A is shown in FIG. 3. A secondcross-sectional view of the axle arm taken along a cutting plane B-B isshown in FIG. 4. An example lubricant level in the lubricant reservoiris illustrated in FIG. 5.

Turning now to FIG. 1, it shows a vehicle 100 comprising a first shaft102 and a second shaft 112. The first shaft 102 may be configured todrive a first set of wheels 104 and the second shaft 112 may beconfigured to drive a second set of wheels 114. In one example, thefirst shaft 102 is arranged near a front of the vehicle 100 and thesecond shaft 112 is arranged near a rear of the vehicle 100.

In one example, the first shaft 102 and the second shaft 112 may includean axle arm housing a driveshaft. The driveshaft may be configured torotate within a lubricant reservoir of the axle arm. When the driveshaftrotates, power may be transferred to the first and second sets ofwheels.

A first electric motor 110 may be arranged on the first shaft 102 and asecond electric motor 120 may be arranged on the second shaft 112. Thefirst electric motor 110 may be configured to drive the first shaft 102,which may result in rotation of the first set of wheels 104. A firstbattery 132 may be configured to supply electrical energy to the firstelectric motor 110. The second electric motor 120 may be configured todrive the second shaft 112, which may result in rotation of the secondset of wheels 114. A second battery 134 may be configured to supplyelectrical energy to the second electric motor 120. In some examples,additionally or alternatively, a single battery may be configured tosupply electrical energy to each of the first electric motor 110 and thesecond electric motor 120.

The vehicle 100 is illustrated as an all-electric vehicle comprising oneor more batteries for powering one or more electric motors to drive thevehicle. In one example, the vehicle 100 is an all-electric passengervehicle. In some examples, additionally or alternatively, the vehicle100 may be a hybrid vehicle including an engine configured to supplypower to one or more of the first shaft 102 and the second shaft 112.

Turning now to FIG. 2, it shows an embodiment 200 of an axle arm 210. Anaxis system includes three axes, namely a longitudinal axis 292, alateral axis 294, and a transverse axis 296. A central axis 299 of theaxle arm 210 is parallel to the longitudinal axis 292. The figure showsthe arm with axis 294 being a vertical axis with respect to a ground onwhich the vehicle travels, and thus illustrating a direction oppositegravity.

The axle arm 210 includes a first end 212 and a second end 214. Thefirst end 212 may correspond to a first extreme end of the axle arm 210.The second end 214 may correspond to a second extreme end of the axlearm 210, opposite the first end 212.

The first end 212 may include an inner opening 216 through which adriveshaft 240 may extend. The first end 212 further includes an outeropening 218 surrounding the inner opening 216. A rim 230 may separatethe inner opening 216 from the outer opening 218. The first end 212 mayfurther include an outer ring 220 shaping an outer circumference of theouter opening. A first flange 222 may extend from the outer ring 220 ina radially outward direction, wherein a diameter of the first flange 222is larger than a diameter of the outer ring 220.

The first flange 222 may include one or more surface features includinga tab 224 and a pair of indentations 226 arranged along its perimeter.In one example, the tab 224 and the indentations 226 may align with agearbox housing, a motor housing, or other type of housing. The firstflange 222 may further include a plurality of dimples 228. The pluralityof dimples 228 may face a direction away from the second end 214.

A first section 232 of the axle arm 210 is coupled to the outer ring 220and extends therefrom. The first section 232 may include a conicalshape. A diameter of the first section 232 may decrease in a directiontoward the second end 214.

A second section 234 may be coupled to the first section 232. The secondsection 234 may include a uniform diameter and extend toward a thirdsection 236 coupled to a second flange 238 of the second end 214. Thesecond section 234 may further include a plurality of surface featuresincluding a plurality of protrusions 235. The plurality of protrusions235 may include one or more ports, ribs, and the like.

The third section 236 may include a conical shape similar to the firstsection 232. The diameter of the third section 236 may decrease in adirection toward the first end 212 and away from the second end.

A lubricant system 280 may be fluidly coupled to a lubricant reservoirarranged within the axle arm 210. The driveshaft 240 may be arrangedwithin the lubricant reservoir, wherein a portion of the driveshaft 240may contact lubricant arranged therein. The lubricant reservoir in whichthe driveshaft 240 may rotate is described in greater detail below.

Turning now to FIGS. 3 and 4, they show a first internal-section 300 anda second internal-section 400, respectively. The first internal-section300 illustrates an interior of the axle arm 210 at the plane A-A of FIG.2. The second internal-section 400 illustrates an interior of the axlearm 210 at the plan B-B of FIG. 2. The first internal-section 300 andthe second internal section 400 include a vantage point from the firstend 212 toward the second end 214.

In FIG. 3, a lubricant reservoir 310 is illustrated along with across-section of the driveshaft 240. In one example, lubricant in thelubricant reservoir 310 is oil. The lubricant reservoir 310 may beshaped to extend through a center of the axle arm 210. The lubricantreservoir 310 may include an upper wall 312, a lower wall 314, a firstside wall 316, and a second side wall 318. The upper wall 312 and thelower wall 314 may be parallel to one another and normal to each of thefirst side wall 316 and the second side wall 318. The first side wall316 may be parallel to the second side wall 318.

A central axis of the driveshaft 240 may be aligned with the centralaxis 299. Herein, central axis 299 may refer to a central axis of theaxle arm 210 and the driveshaft 240. In prior art examples including anaxle arm and a lubricant reservoir including a driveshaft, an upper walland a lower wall of the lubricant reservoir are equidistant to thecentral axis of the axle arm and the driveshaft. By doing this, an airgap between the driveshaft and the lower wall may be relatively large,resulting in a large amount of lubricant contained in the lubricantreservoir.

In the example of FIGS. 3 and 4, the dimensions of the lubricantreservoir 310 are adjusted relative to prior art examples withoutadjusting a corresponding section of the axle arm 210. By doing this,the amount of lubricant contained within the lubricant reservoir 310 isreduced, increasing a quantity of lubricant available for othercomponents.

The lubricant reservoir 310 may be sized relative to the position of thedriveshaft 240. A size of an air gap, defined by first dimension 352,may be reduced relative to the prior art examples. In one example, thefirst dimension 352 measures from an inner perimeter of the lower wall314 to the central axis 299. The first dimension 352 may be less than adiameter 340 of the driveshaft 240.

A bottom distance 362 may measure from an outer perimeter of the lowerwall 314 to the central axis 299. Thus, the bottom distance 362 isgreater than the lower wall 314. A top distance 364 may measure from thecentral axis 299 to an outer perimeter of the upper wall 312. The topdistance 364 may be greater than the bottom distance 362. Thus, acentral axis 399 of the lubricant reservoir 310 may be misaligned withthe central axis 299. In one example, the central axis 399 of thelubricant reservoir 310 is above the central axis 299. The reduction ofthe bottom distance and the first dimension 352 results in a reductionof the size of the air gap and less lubricant housed in the reservoir.

A second dimension 354 may measure from the upper wall 312 to thecentral axis 299. The second dimension 354 in the example of FIGS. 3 and4 may be equal to a second dimension of the prior art examples. However,in the example of the present disclosure, the first dimension 352 isless than the second dimension 354, whereas in the prior art examplesthe first dimension is equal to the second dimension. By shaping thelubricant reservoir to reduce the size of the air gap without adjustingdimensions of the axle arm, an amount of lubricant below the driveshaftaxis is reduced without impacting the axle arm 210 performance andstrength. In one example, the dimensions of the lubricant reservoir 310are adjusted to reduce an amount of lubricant arranged therein to aminimum threshold level. In one example, the minimum threshold level isbased on a lowest amount of lubricant in the lubricant reservoir with afill line still contacting a portion of the driveshaft 240.

As illustrated, a shape of the lubricant reservoir 310 may transition toa more rectangular shape from the first internal-section 300 to thesecond internal-section 400. In some examples, additionally oralternatively, the lubricant reservoir 310 may maintain a uniform shapethrough a longitudinal length of the axle arm 210 from the firstinternal-section 300 to the second internal-section 400.

Turning now to FIG. 5, it shows an example 500 of the lubricantreservoir 310 including lubricant arranged therein. In one example, thelubricant is oil. The lubricant reservoir may be filled with lubricantto a threshold fill line 502. In one example, the threshold fill line502 corresponds to a fill line resulting in the oil level contacting atleast a portion of the driveshaft 240. In one example, the thresholdfill line contacts at least a bottom portion of the driveshaft 240. Asthe driveshaft 240 rotates, various portions of its circumference maycontact the oil level, resulting in an entirety of the driveshaft 240being lubricated with the reduced threshold fill line.

The technical effect of adjusting the lubricant reservoir dimensionswithout adjusting an axle arm size or driveshaft position is to decreasean amount of lubricant demanded to lubricate the driveshaft. By doingthis, manufacture and assembly of the axle arm and driveshaft may beminimally adjusted while increasing a lubricant availability to othercomponents of a lubricant system.

The disclosure provides support for a system including a lubricantreservoir of an axle arm comprising a fill line at an edge of adriveshaft, wherein a central axis of the lubricant reservoir ismisaligned with a central axis of the driveshaft. A first example of thesystem further includes where the lubricant reservoir is arranged in anaxle arm. A second example of the system, optionally including the firstexample, further includes where the central axis of the driveshaftaligns with a central axis of the axle arm. A third example of thesystem, optionally including one or more of the previous examples,further includes where interior surfaces of the axle arm shape thelubricant reservoir. A fourth example of the system, optionallyincluding one or more of the previous examples, further includes where afirst dimension measured from a bottom surface of the axle arm to thecentral axis of the driveshaft is less than a second dimension measuredfrom a top surface of the axle arm to the central axis of thedriveshaft. A fifth example of the system, optionally including one ormore of the previous examples, further includes where the firstdimension is less than a diameter of the driveshaft. A sixth example ofthe system, optionally including one or more of the previous examples,further includes where a bottom distance measured from an outerperimeter of a bottom surface of the axle arm to the central axis of thedriveshaft is less than a top distance measured from an outer perimeterof a top surface of the axle arm to the central axis of the driveshaft,wherein the bottom surface and top surface shape the lubricantreservoir. A seventh example of the system, optionally including one ormore of the previous examples, further includes where the edge of thedriveshaft corresponds to a portion of the drive shaft nearest thebottom surface. An eighth example of the system, optionally includingone or more of the previous examples, further includes where the fillline is below the central axis of the drive shaft.

The disclosure further provides support for an axle arm including adriveshaft arranged in a lubricant reservoir, wherein a fill line oflubricant reservoir contacts a bottom portion of the driveshaft. A firstexample of the axle arm further comprises where the bottom portion is abottommost portion of the driveshaft. A second example of the axle arm,optionally including the first example, further includes where a centralaxis of the lubricant reservoir is misaligned with a central axis of thedriveshaft. A third example of the axle arm, optionally including one ormore of the previous examples, further includes where a first dimensionmeasuring a height of an air gap from the central axis of the driveshaftto a lower wall is less than a second dimension measuring a height ofthe air gap from the central axis of the driveshaft to an upper wall,wherein the upper and lower walls define a portion of a perimeter of thelubricant reservoir. A fourth example of the axle arm, optionallyincluding one or more of the previous examples, further includes wherelubricant in the lubricant reservoir is oil. A fifth example of the axlearm, optionally including one or more of the previous examples, furtherincludes where the lubricant reservoir changes in shape from a first endof the axle arm to a second end of the axle arm, the second end oppositethe first end.

The disclosure further provides support for a system including an axlearm comprising an upper wall, a lower wall, a first lateral wall, and asecond lateral wall, a lubricant reservoir shaped by the upper wall, thelower wall, the first lateral wall, and the second lateral wall, and adriveshaft configured to rotate within the lubricant reservoir, whereina central axis of the driveshaft is aligned with a central axis of theaxle arm and misaligned with a central axis of the lubricant reservoir.A first example of the system further includes where the central axis ofthe driveshaft is closer to the lower wall than the upper wall. A secondexample of the system, optionally including the first example, furtherincludes where the central axis of the lubricant reservoir is verticallyabove the central axis of the driveshaft. A third example of the system,optionally including one or more of the previous examples, furtherincludes where the axle arm is arranged in an electric vehicle. A fourthexample of the system, optionally including one or more of the previousexamples, further includes where a fill line of the lubricant reservoircontacts only a perimeter of the driveshaft.

FIGS. 1-5 show example configurations with relative positioning of thevarious components. If shown directly contacting each other, or directlycoupled, then such elements may be referred to as directly contacting ordirectly coupled, respectively, at least in one example. Similarly,elements shown contiguous or adjacent to one another may be contiguousor adjacent to each other, respectively, at least in one example. As anexample, components laying in face-sharing contact with each other maybe referred to as in face-sharing contact. As another example, elementspositioned apart from each other with only a space there-between and noother components may be referred to as such, in at least one example. Asyet another example, elements shown above/below one another, at oppositesides to one another, or to the left/right of one another may bereferred to as such, relative to one another. Further, as shown in thefigures, a topmost element or point of element may be referred to as a“top” of the component and a bottommost element or point of the elementmay be referred to as a “bottom” of the component, in at least oneexample. As used herein, top/bottom, upper/lower, above/below, may berelative to a vertical axis of the figures and used to describepositioning of elements of the figures relative to one another. As such,elements shown above other elements are positioned vertically above theother elements, in one example. As yet another example, shapes of theelements depicted within the figures may be referred to as having thoseshapes (e.g., such as being circular, straight, planar, curved, rounded,chamfered, angled, or the like). Further, elements shown intersectingone another may be referred to as intersecting elements or intersectingone another, in at least one example. Further still, an element shownwithin another element or shown outside of another element may bereferred as such, in one example. It will be appreciated that one ormore components referred to as being “substantially similar and/oridentical” differ from one another according to manufacturing tolerances(e.g., within 1-5% deviation).

As used herein, the term “approximately” is construed to mean plus orminus five percent of the range unless otherwise specified.

The following claims particularly point out certain combinations andsub-combinations regarded as novel and non-obvious. These claims mayrefer to “an” element or “a first” element or the equivalent thereof.Such claims should be understood to include incorporation of one or moresuch elements, neither requiring nor excluding two or more suchelements. Other combinations and sub-combinations of the disclosedfeatures, functions, elements, and/or properties may be claimed throughamendment of the present claims or through presentation of new claims inthis or a related application. Such claims, whether broader, narrower,equal, or different in scope to the original claims, also are regardedas included within the subject matter of the present disclosure.

1. A system for a vehicle, comprising: an axle arm having a lubricantreservoir, the lubricant reservoir comprising a fill line at an edge ofa driveshaft, wherein a central axis of the lubricant reservoir isvertically misaligned with a central axis of the driveshaft; and alubricant system coupled to the lubricant reservoir.
 2. The system ofclaim 1, wherein the vertically misalignment is with respect to gravity.3. The system of claim 2, wherein a first dimension measured from abottom surface of the axle arm to the central axis of the driveshaft isless than a second dimension measured from a top surface of the axle armto the central axis of the driveshaft.
 4. The system of claim 3, whereinthe central axis of the driveshaft aligns with a central axis of theaxle arm.
 5. The system of claim 4, wherein interior surfaces of theaxle arm shape the lubricant reservoir.
 6. The system of claim 5,wherein the first dimension is less than a diameter of the driveshaft.7. The system of claim 2, wherein a bottom distance measured from anouter perimeter of a bottom surface of the axle arm to the central axisof the driveshaft is less than a top distance measured from an outerperimeter of a top surface of the axle arm to the central axis of thedriveshaft, wherein the bottom surface and top surface shape thelubricant reservoir.
 8. The system of claim 2, wherein the edge of thedriveshaft corresponds to a portion of the drive shaft nearest thebottom surface.
 9. The system of claim 1, wherein the fill line isvertically below the central axis of the drive shaft.
 10. An axle armsystem, comprising: a driveshaft arranged in a lubricant reservoir,wherein a fill line for lubricant of a lubricant reservoir contacts abottom portion of the driveshaft; and a lubricant system coupled to thelubricant reservoir.
 11. The system of claim 10, wherein the bottomportion is a bottommost portion of the driveshaft.
 12. The system ofclaim 10, wherein a central axis of the lubricant reservoir ismisaligned with a central axis of the driveshaft.
 13. The system ofclaim 12, wherein a first dimension measuring a height of an air gapfrom the central axis of the driveshaft to a lower wall is less than asecond dimension measuring a height of the air gap from the central axisof the driveshaft to an upper wall, wherein the upper and lower wallsdefine a portion of a perimeter of the lubricant reservoir.
 14. Thesystem of claim 10, wherein lubricant in the lubricant reservoir is oil.15. The system of claim 14, wherein the lubricant reservoir changes inshape from a first end of the axle arm to a second end of the axle arm,the second end opposite the first end.
 16. A system, comprising: an axlearm comprising an upper wall, a lower wall, a first lateral wall, and asecond lateral wall; a lubricant reservoir shaped by the upper wall, thelower wall, the first lateral wall, and the second lateral wall; and adriveshaft configured to rotate within the lubricant reservoir, whereina central axis of the driveshaft is vertically aligned with a centralaxis of the axle arm and vertically misaligned with a central axis ofthe lubricant reservoir.
 17. The system of claim 16, wherein the centralaxis of the driveshaft is closer to the lower wall than the upper wall.18. The system of claim 16, wherein the central axis of the lubricantreservoir is vertically above the central axis of the driveshaft. 19.The system of claim 16, wherein the axle arm is arranged in an electricvehicle.
 20. The system of claim 16, wherein a fill line of thelubricant reservoir contacts only a perimeter of the driveshaft.